Apparatus and process for preparing confectionery having an inclusion therein using forming rolls and a forming pin

ABSTRACT

The present invention is directed to a forming apparatus comprising (a) first and second forming rolls with forming pockets in corresponding alignment, wherein at least one roll has one or more continuous grooves extending around the circumference of the roll in a plane perpendicular to the longitudinal axis of the roll and which intersects the forming pockets in the plane, wherein the first and second forming rolls rotate in directions counter to one another, and (b) one or more forming pins positioned between the counter rotating rolls and within the continuous groove of the roll.

RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.10/900,174, filed Jul. 28, 2004, now U.S. Pat. No. 7,621,734 on Nov. 24,2009, the entire content of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an apparatus and process for makingshaped confectionery products from a fat based material, e.g.,chocolate. More particularly, the present invention relates to anapparatus and process used in making shaped confectionery centers by aforming process, such as cold forming, where the shaped confectionerycenters have an internal hollow section.

2. Description of the Related Art

Confectionery centers may be manufactured by various methods, includingdrop roll forming techniques where a liquid material is depositedthrough a set of forming rolls or cold forming of centers from solidparticulate. Drop roll forming is well known in the art and described in“Chocolate, Cocoa, and Confectionery Science and Technology,” 3^(rd)ed., (1999) pp. 184-186, by B. W. Minifie. Cold forming is described inU.S. Pat. No. 6,270,826 for forming confectionery centers by takingsolid particles of a fat based material such as chocolate flakes andcompressing the particles in a set of forming rolls. The confectionerycenters produced from either of these methods are typically furtherprocessed by applying a sugar shell coating over the outside of thecenters.

When these sugar shelled confectionery products have a fat based center,they tend to develop quality problems when exposed to heat. This isevident in warm climates where shell cracking and fat bleeding are majorconsumer issues. The heat in the warm climate causes thermal expansion,which leads to cracks in the shell and ultimately enables fat to bleedthrough the shell.

One method that has been found to reduce thermal expansion issues is toaerate the fat based material that is used to form the fat based center.Compressed air is added into the fat based material when it is a liquidto create a homogenous dispersion of small void spaces. It ishypothesized that when thermal treatment is applied, e.g. highertemperatures, the presence of the hollow section in the formedconfectionery center enables the fat based material to expand partiallyinto the void space, thus reducing the expansion forces on the shell.

However, aeration methods have several disadvantages. When drop rollforming methods are used to form centers from liquid, the level ofaeration in the formed confectionery center is very limited. Typically,the pressure exerted by the drop rolls squeezes some of the compressedair out of the fat based material as the fat based centers are formed.As this process occurs, air trapped in the liquid is squeezed out andreleased into the environment. Prior art aeration techniques with liquidchocolate have only managed to incorporate less than 4.65% by weight ofthe air into the fat based material. However, at these low levels ofaeration the benefit is only apparent up to certain temperatures. Ahigher level of aeration is desirable to increase the benefits gainedfrom the void spaces, further reducing and eliminating expansion andcracking defects. Aerating the fat based material when using drop rollscan also be costly, creating a continuous expense since compressed airmust be constantly blended into the fat based material. Moreover,aeration techniques add to the complexity of the manufacturing processand often produce inconsistent results.

When using cold forming technology, it is not possible to use aerationto form a confectionery center with void spaces. As mentioned above,compressed air can be added to a liquid to create an aerated material.In cold forming technology, solid particles are compressed to form ashaped confectionery center. This would require having the liquidaerated confectionery material first be solidified then formed intosmall particulates before forming it into shaped centers. This processwould destroy much of the voids created during aeration. Additionally,the cold forming process itself would exert a higher level of pressureon the confectionery material than a drop roll process compressing andreleasing much of the trapped air.

A means of preventing or reducing product issues related to heatexposure would improve product quality and be more appealing toconsumers. A means of creating confectionery centers produced by coldforming, which have the benefits of aeration is needed. Overall, ahigher level of void spaces (aeration or density reduction) is desiredfor increased benefits in product quality of sugar shelled confectionerycenters.

SUMMARY OF THE INVENTION

The present invention is directed to a forming apparatus comprising (a)first and second forming rolls with forming pockets in correspondingalignment, wherein at least one roll has one or more continuous groovesextending around the circumference of the roll in a plane perpendicularto the longitudinal axis of the roll and which intersects the formingpockets in the plane, wherein the first and second forming rolls rotatein directions counter to one another, and (b) one or more forming pinspositioned between the counter rotating rolls and within the continuousgroove of the roll.

In another aspect, the present invention also includes a process formanufacturing a shaped confectionery product. The method comprises thesteps of (a) providing a fat based material to a forming apparatus,wherein the forming apparatus comprises (i) first and second formingrolls with forming pockets in corresponding alignment, wherein at leastone roll has one or more continuous grooves extending around thecircumference of the roll in a plane perpendicular to the longitudinalaxis of the roll and which intersects the forming pockets in the plane,and wherein the first and second forming rolls rotate in directionscounter to one another; and (ii) one or more forming pins positionedbetween the counter rotating rolls and within the continuous grooves ofthe rolls; (b) forcing the fat based material through the formingapparatus, thereby substantially forming the shaped confectioneryproduct; and (c) optionally, cooling the shaped confectionery product.

In another embodiment of the present invention, a panned sugar shelledconfectionery is made by the process comprising the steps of (a)providing a fat based material to a forming apparatus, wherein theforming apparatus comprises (i) first and second forming rolls withcorresponding forming pockets, wherein at least one roll has one or morecontinuous grooves extending around the circumference of the roll in aplane perpendicular to the longitudinal axis of the roll and whichintersects the forming pockets in the plane; and wherein the first andsecond forming rolls rotate in a direction counter to one another, and(ii) at least one forming pin positioned between the counter rotatingrolls and within the continuous grooves of the rolls; (b) forcing thefat based material through the forming apparatus, thereby forming shapedconfectionery centers; (c) applying a coating onto the shapedconfectionery centers, thereby forming the panned sugar shelledconfectionery; and (d) optionally, including one or more of thefollowing steps: (i) cooling the shaped confectionery centers after theshaping step; (ii) deflashing a webbing formed during the shaping step;and (iii) rolling the shaped confectionery centers after the shapingstep.

The invention also includes a panned sugar shelled product having acenter that has a percent density reduction of at least about 5%.Preferably, the center is a chocolate center.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a cross sectional view of ashaped chocolate center made using the apparatus of the invention;

FIG. 2 is a schematic representation of the overall process andapparatus of the present invention;

FIG. 3 is a partial perspective view showing the essential features ofthe apparatus of the present invention;

FIG. 4 is a cut away cross sectional view of a set of forming rolls anda forming pin;

FIG. 5 is a top view of a forming roll illustrating one embodiment offorming pockets positioned on the forming roll to form a shaped productwith a longitudinal groove;

FIG. 6 shows a partial perspective view where a forming pin ispositioned on a forming pocket and along a groove that extends along thecircumference of the roll;

FIG. 7 a is a top view of a portion of a sheet of chocolate centers madeusing the apparatus of the invention;

FIG. 7 b is a top view of a portion of a sheet of chocolate centers madeusing standard forming rolls;

FIG. 8 a is a schematic representation of a perspective view of a lentilshaped center with a void space sealed within the center;

FIG. 8 b is a schematic representation of a top view of a lentil shapedcenter;

FIG. 9 a is a perspective view of one embodiment of a forming pin; and

FIG. 9 b is a top view of the forming pin of FIG. 9 a.

DETAILED DESCRIPTION OF THE INVENTION

For the purposes of this invention, “fat-based” refers to a materialhaving a fat or lipid continuous phase in which material components suchas, for example, milk proteins and sugars are dispersed.

The term “chocolate” is intended to refer to all chocolate orchocolate-like compositions with a fat phase or fat-like composition.The term is intended, for example, to include standardized andnon-standardized chocolates, i.e., including chocolates withcompositions conforming to the U.S. Standards Of Identity (SOI) andcompositions not conforming to the U.S. Standards Of Identity,respectively, including dark chocolate, baking chocolate, milkchocolate, sweet chocolate, semi-sweet chocolate, buttermilk chocolate,skim-milk chocolate, mixed dairy product chocolate, low fat chocolate,white chocolate, aerated chocolates, compound coatings, non-standardizedchocolates and chocolate-like compositions, unless specificallyidentified otherwise.

The presence of a void or hollow section in a product made by theprocess of the invention results in a reduction in product density.Visually, the product of the invention appears to be solid. However, thehollow section formed within the product decreases the weight of theproduct. As the volume of the hollow section increases, the density ofthe product decreases. The change in density can be quantified bycalculating the percent density reduction.

The equation(w1−w2)/w1×100%is used to calculate the percent density reduction, where w1 is equal tothe total weight of the a formed center prior to treatment, and w2 isequal to the total weight of the product after treatment. Alternatively,the equation(d1−d2)/d1×100%maybe used, where d1 is equal to the density of the center prior totreatment, and d2 is the density of the center after treatment. Thedensity of a product made using the forming pin of this invention has avoid or hollow section that results in a lower density value than asimilar product that is solid and made of the same material.

For example, two chocolate products are made using a cold formingprocess. The first product is made using the method described in U.S.Pat. No. 6,270,826, where solid center pieces are produced. The secondproduct is made using the process of the invention where a pin is usedto form a void in the center pieces. The first product has a density ofabout 1.29 g/cc, and the second product has a density of about 1.23g/cc. The difference in densities between the two products divided bythe density of the solid center pieces provides the percent densityreduction of the product. In this case the percent density reduction is4.65%.

In FIG. 1, a schematic representation of a cross sectional view of theinternal body of a shaped confectionery center is shown revealing ahollow section formed by the pin. In this particular embodiment, thehollow section has ends that are sealed by the fat based material andthe hollow section extends through a substantial portion of the center.The sealed ends are formed during processing by a lip projecting fromthe body of the shaped confectionery center adjacent to the hole, whichis folded into the hole as the center is rolled. It becomes apparentthat the density of the shaped confectionery piece of the invention isless than a solid piece of similar size.

The hollow section formed within the shaped product has been found toprovide desirable quality benefits. The inventors have discovered thatthe presence of the hollow section in the confectionery productincreases the robustness of the shelled shaped confectionery productwhen exposed to higher temperatures. The result is a lower incidence ofcracking and fat bleeding through the shell. This has been confirmedthrough thermal cycle testing which demonstrates the robustness of theshelled shaped confectionery product of the invention. It ishypothesized that when thermal treatment is applied, the presence of thehollow section enables the fat based material to expand partially intothe void space, thus reducing the expansion forces on the shell andkeeping it from cracking. By maintaining the shell's integrity thelikelihood of fat, e.g., cocoa butter, bleeding through the shell isdramatically reduced. This provides a solution to the product issuesencountered in warm climates, where heat exposure may detrimentallyaffect the product's exterior.

The forming apparatus of the present invention includes a forming deviceand at least one forming pin. Various forming devices may be used, suchas, drop rolls, which are described by B. W. Minifie, in his booktitled, “Chocolate, Cocoa, and Confectionery Science and Technology,”3^(rd) ed., (1999) pp. 184-186, the contents of which are incorporatedby reference. Another example of a forming device is a cold formingdevice, such as the one described in U.S. Pat. No. 6,270,826.Preferably, the forming device is a cold forming apparatus comprised offirst and second forming rolls which have corresponding formingcavities/pockets in each roll. The forming pockets mate as the formingrolls rotate. The rolls are mounted for counter rotation with no or aslight space between the rolls and a hopper is provided above thecounter-rotating rolls to direct, by a gravity feed, the confectionerymaterial in the form of flakes, shavings or granules to the rolls. Thecounter-rotating rolls draw the fat based material, e.g. chocolatepieces, down between the nip of the rolls to compress and compact thechocolate pieces in a process akin to sintering to form the chocolateinto the desired shape. The chocolate leaves the rolls in a downwarddirection in sheet form with the formed chocolate pieces interconnectedby a thin web of chocolate. The depression on each roll need not beidentical as a character figure can be made with a back side and a frontside which is different. The important consideration is that eachimpression as it mates in the nip aligned so that a piece is formedhaving similar radial dimensions.

Another important feature is a continuous groove which extends aroundthe circumference of at least one of the rolls in a plane perpendicularto the longitudinal axis of the roll and which intersects the formingpockets in the same plane. In a preferred embodiment, each forming rollhas a groove, where the groove in one roll is matched to a correspondinggroove in the other roll. Preferably, there are multiple grooves withmatching corresponding grooves. Thus, when the rolls are in properalignment and contact with one another, the grooves line up to form achannel. In one embodiment, more than one continuous groove intersects asingle forming pocket.

The forming pin is the other essential component of the apparatus of theinvention. The pin preferably has a long narrow body. Ideally, the pinis an elongated cylindrical rod. However the pin may be, for example, anelongated rectangular, square, oval, triangular, or other elongated rodshaped variant. The main criteria is that the pin fit into the groovewhere the tolerance is such that the pin does not contact or interferewith the forming rolls as they rotate. Yet the pin should fit closeenough in the groove to prohibit the fat based material from building upin the space between the groove and the pin where the forming rollsmeet. Ideally, the tolerance between the pin and the groove is about0.01 to about 0.02 inches (about 0.25 mm to about 0.51 mm).

The dimensions of the pin are dependent upon several factors includingproduct design requirements, the desired mechanical strength of theformed shaped pieces, and the shape of the shaped product. As a generalguideline, the width and depth of the forming pin is about 10% to about80% of the width and depth of the forming pocket. Preferably the widthand depth is about 25% to 75%, and more preferably about 35% to 70% ofthe width and depth of the forming pocket. The length of the pin isgenerally designed so that when it is attached to the structuresupporting it, the body of the pin extends beyond the length of theforming pocket as it mates in the nip. Alternatively, the forming pinmay be characterized by the volume it displaces in the shaped product inpercentage terms. Typically, the forming pin is sized to fill ordisplace about 0.05% to about 70% by volume (vol. %) of the total volumeof the shaped product formed. Preferably about 4 vol. % to about 65 vol.%, more preferably about 4.5 vol. % to about 60 vol. %, and even morepreferably 5.0% to 60% is displaced by the forming pin. Additionally,the pin should be sized to provide a shaped product that has at least aminimal amount of wall material to give the shaped product sufficientmechanical strength to maintain its' shape during forming and postprocessing. This is largely a function of the properties of the fatbased material.

The forming pin is preferably constructed of a metal that has a surfacehardness, which will resist wearing of the pin. A preferred choice ofmetal is anodized aluminum, which is very hard and wear resistant andprovides high tensile strength. However, other metals such as forexample, carbon steel, stainless steel, and the like may be used toconstruct the pin. Metal also provides the pin with good thermalconductivity properties, which may be useful to maintain the optimalsurface temperature of the pin. For example, to minimize chocolatesticking to the pin, it is important to maintain the temperature above20° C. In addition, the required mechanical properties of the metal, theshape geometry, and lengths are important to maintain alignment andprevent contact between the forming rolls and the pin.

A surface adhesion reducing agent such as Teflon, silicone, and the likemay be used to treat the pin. Preferably, the surface adhesion reducingagent is Teflon. The presence of the coating reduces sticking of the fatbased material to the pin. The pin may also be treated with a temporarycoating that functions as a surface adhesion reducing agent or ifwarranted a permanent coating may be applied.

As previously mentioned, the pin is positioned in the apparatus of theinvention so that it fits into a groove, ideally where the forming rollsmeet in the nip. By adjusting the height of the end of the pin relativeto the nip of the roll, the cavity created by the pin may be varied. Ina preferred embodiment the pin is mounted above the nip region and ispositioned so the body of the pin extends just beyond the bottom of theforming cavity when that forming cavity is centered at the nip of theforming rolls. Any suitable means may be used to support the pin in sucha position, so long as it does not interfere with the movement of theforming rolls. In one embodiment, a bridge is constructed betweenopposing walls of the hopper positioned above the rolls, and the formingpins are suspended from the bridge.

Moreover, the pin may be situated in a fixed position that is alignedbetween the rolls. In an alternative embodiment, the pin may oscillateand/or vibrate. The oscillating and/or vibrating motion, aids in formingan empty cavity and assists in reducing the adhesion of the fat basedproduct to the pin.

As described above, the forming pin serves to create a void within thecenter piece that is formed. However, the pin may also provide otheruseful purposes. For example, the pin may function as a probe, whichsenses for example, temperature and/or viscosity. In another embodiment,the pin may be designed with heating and/or cooling means.

In a preferred embodiment, the inside of the pin is hollow and there isa hole in the body of the pin. Preferably the hole is located in closeproximity to the head of the pin. In such a configuration, the pin canbe used to inject a filling into the center of a shaped piece. Forexample, the inside of the pin can be used to hold a filling, which canbe injected into the empty cavity created by the pin. Preferably, thefilling is injected intermittently so that it will fill the centers butnot the web.

A variety of fillings may be added through the pin. For example, thefilling may be caramel, nougat, jelly, cream, a flavored liquid,mixtures thereof, and the like.

Furthermore, an outer coating may be applied over the center pieces.Typically, the coating is applied using a panning operation. Forexample, the shaped confectionery centers may be coated with a sugarshell coating. The percent shell coating that is applied will impact theoverall design of the product in several ways, including the perceivedcrunch of the product (e.g., too little or too much crunch), the amountof coverage over the product, and the adherence of the shell to theshaped center. The outer coating that is applied is preferably about 15%to about 40% by weight of the total weight of the shaped confectioneryproduct, preferably about 20% to about 38%, and most preferably about23% to about 35%. In a preferred embodiment, a hard panned sugar shellis applied over the shaped center.

The apparatus of the present invention is used for manufacturing ashaped confectionery product, e.g., confectionery centers. The method ofmanufacturing such products comprises the steps of (a) providing a fatbased material to a forming apparatus, wherein the forming apparatuscomprises (i) first and second forming rolls with forming pockets incorresponding alignment, wherein at least one roll has one or morecontinuous grooves extending around the circumference of the roll in aplane perpendicular to the longitudinal axis of the roll and whichintersects the forming pockets in the plane, and wherein the first andsecond forming rolls rotate in directions counter to one another; and(ii) one or more forming pins positioned between the counter rotatingrolls and within the continuous grooves of the rolls; (b) forcing thefat based material through the forming apparatus, thereby substantiallyforming the shaped confectionery product; and (c) optionally, coolingthe shaped confectionery product. In addition, a filling may be added byinjecting the filling through the forming pin.

Preferably the fat based material is a free flowable particulatematerial, which has a particle diameter less than one half the diameterof the forming pocket. It has been found that smaller particles have nodetrimental effect on the process, while large particles may lead toinsufficiently filled pockets that yield incomplete centers.

The fat based material may be any edible material having a continuousfat or lipid phase. The preferred fat based material is chocolate.

The forcing step compacts and compresses the flowable particulate, i.e.fat based material into the desired shape.

In a preferred embodiment the shaped confectionery centers have adensity reduction of at least about 5%. It is also desirable that thesecenters have non-homogenous void spaces. One, two, or three void spacesare preferred.

The shaped confectionery centers may be treated to a deflashing step toremove the webbing formed during the shaping step. Typically, the fatbased material passes through the forming rolls producing a sheetcontaining the shaped centers. The sheet is then cooled in a coolingtunnel or chamber and then sent to a deflashing operation. Here, theshaped confectionery centers are agitated to break apart the webbing ofthe sheet and smooth the edges where the web interconnects the formedpieces. One effective method of removing the webbing is to roll theshaped centers in a rotating drum or tube, where perforations are placedalong the drum or tube walls. To prevent the shaped centers from fallingthrough the perforations, the perforations are sized smaller than theshaped centers. Alternatively, the shaped centers may be placed on aperforated vibratory conveyor or screen to remove the webbing. In a morepreferred embodiment the shaped confectionery centers are treated to arolling step. Typically after the deflash step, rough edges and smallpieces from the webbing remain the centers. During the rolling step, thecenters are rolled in a drum or tube. The forced motion of the centersagainst other centers and the pressing action of the centers against theedges of the tube or drum creates friction which slightly warms thecenters and smoothes the rough edges, removing the excess chocolateremaining on the centers. Deflashing or rolling may be performed on abatch or continuous basis.

The shaped confectionery centers may then be further processed, ifdesired, by applying a sugar shell coating. A detailed description ofpanning can be found in B. W. Minifie, “Chocolate, Cocoa, andConfectionery Science and Technology,” 3^(rd) ed., (1999) pp. 184,221-223, 506, 608-609, and 613, the contents of which is incorporated byreference.

In FIG. 2, apparatus 10 of the present invention includes a pair ofcounter-rotating forming rolls 18 and 20, which rotate toward each otherin the direction indicated by the arrows. Forming rolls 18 and 20 areprovided, as will be explained below, with forming pockets, which mateas the form rolls rotate, to force the fat based material into theforming pockets into the desired shape. In addition, at least one,preferably both rolls has at least one continuous groove which extendsaround the circumference of the roll in a plane perpendicular to thelongitudinal axis of the roll. The continuous groove also intersects theforming pockets in the plane perpendicular to the longitudinal axis ofthe roll. Preferably, there are multiple grooves and correspondinggrooves in the rolls. Above rolls 18 and 20 is hopper 16, which containsthe fat based material that is fed into the rolls. Forming pin 15extends downward from bridge 17 into hopper 16 and is positioned to restin the channel formed at the meeting point where a longitudinal grooveon roll 18 and a corresponding longitudinal groove on roll 20 meet.

In FIG. 3, hopper 16 is positioned above forming rolls 18 and 20. Bridge17 is positioned between hopper walls 23 and 24 of the hopper, so thatforming pin 15 can be supported from the bridge. The end of the pinrests in the channel formed by grooves 26 and 27.

In FIG. 4, a cut away side view is shown where forming pin 15 ispositioned in the nip where forming rolls 18 and 20 meet. FIG. 4 alsoshows forming pockets 66, which are situated on the surface of theforming rolls. The forming pockets are positioned on the rolls so thatthey are in corresponding alignment.

In one particularly preferred embodiment, the forming pocket/cavity onat least one of the forming rolls is designed so that the resultingshaped confectionery centers have a lip or tail protruding from the mainbody of the confectionery centers. The lip or tail protrusion is in anarea adjacent to the opening or openings, i.e. holes created by the pinor pins. During the rolling step, the lip or tail is forced over theopening and smoothed to seal it. If the opening is left unsealed, itcould result in flaws in the subsequent coating, by panning for anexample, such as an uneven surface or thin or no coating in some areas.The coating could be added at a higher percentage of the finishedproduct to compensate, however this is not desirable as describedpreviously.

In FIG. 5, a top view of the surface of form roll 18 of the invention isshown. Forming pockets 66 are laid out in a pattern which will alignwith forming pockets on form roll 20. Grooves 63 extend around thecircumference of the roll in a plane perpendicular to the longitudinalaxis of the roll. In addition, the grooves intersect the forming pocketsin the plane.

In FIG. 6, form roll 18 is shown with the end of forming pin 15 restingin forming pocket 66. Intersecting the forming pocket is groove 63.

As previously discussed, the fat based material exits the forming rollsin the form of a continuous sheet. The sheet is comprised of compactedand cohesive shaped centers as well as a webbing between the centers.FIG. 7 a shows a portion of a sheet that is formed using the apparatusof the invention, where the webbing has a raised channel extendingbetween the shaped pieces formed.

In contrast, the centers made using a standard forming apparatus areinterconnected in a webbing that is primarily a flat sheet, as shown inFIG. 7 b.

Referring back to FIG. 2, as the formed sheet exits the apparatus of theinvention, it may be directed to a rotating deflash drum, which rotatesto separate the formed shaped centers, e.g., chocolate centers from thethin interconnecting web. From the deflash drum the formed pieces aredirected, as indicated by arrow 36, for further processing and thedisconnected webs of the fat based material are directed, as indicatedby arrow 38, to another location where it can be recovered and reused asa feed material in the process.

Forming pockets 66 may be of any desired shape to achieve the desiredshaped confectionery product. In a preferred embodiment the formingpockets 66 are shaped to make a lentil shape for subsequent sugar shellcoating to make a product such as M&M's® candy. It has been found thatother desired shapes such as character figures, stars, hearts, eggs andother shapes may be employed as well. However, because of the nature ofthe fat based material, e.g., chocolate, has been found that shapes witha rounded peripheral extent are best to provide a good release angle toallow the formed sheet to readily disengage from the form rolls.

If the fat based material is chocolate, the chocolate flakes or granulesat the start of the process are at ambient temperature. However, when itis compacted, the pressure exerted by the compressive force as thechocolate passes through the nips of the form rolls causes the surfaceof the chocolate in contact with the form rolls to rise and would resultin the chocolate adhering to the surface of the form rolls so as toretard the release of the formed sheet from the form rolls. Accordingly,it is desirable to provide coolant to maintain the surface of the formrolls within a preferred temperature range of 14° C. to 20° C.

The diameter of the forming roll is partially dependent upon the overallsize of the piece to be formed to insure repeatable disengagement of thesheet from the form roll without degradation of the product shape. Ithas been found that with form rolls having an outer diameter of about 28cm to form a lentil shape as used for the size of an M&M's® candy aforming cavity having an length and width of about 12.19 mm and amaximum depth of about 2.74 mm may be effectively employed.

Typically, a matching set of forming pockets will have one forming pin,which may reside in a corresponding groove. In a particular embodiment,however, the apparatus of the present invention has two or more formingpins that intersect a matching set of forming pockets, where the formingpins each reside in corresponding grooves. The multiple pins enable agreater percent density reduction to be achieved, since the multiplepins result in higher void volumes in the shaped piece. When multiplepins are used, the pins are typically smaller in diameter. This requiresgreater care in designing the pins, which must take into account thepins proximity to the wall of the shaped piece and the strength of thepin, i.e., its resistance to bending.

In a preferred embodiment, the forming pockets are designed so that theresulting shaped confectionery centers have at least one lip or tailprojection in an area adjacent to the opening or openings created by thepin or pins. The lip or tail is designed to fold into and over asubstantial portion of the opening created by the pin during processing,i.e., as the centers are rolled.

In FIGS. 8 a and 8 b, a schematic representation of a shapedconfectionery center made using the apparatus of the invention is shown.In FIG. 8 a the width and depth of a center is shown, while FIG. 8 bshows the width and length of the center.

One embodiment of a forming pin is depicted in FIGS. 9 a and 9 b. FIG. 9a shows the forming pin in a perspective view where the length of thepin is apparent. In FIG. 9 b, the top view enables the width and depthto be seen.

The shaped confectionery centers have a percent density reduction of atleast about 5%, more preferably about 5.5%, even more preferably about6%, still even more preferably about 6.5%, still even more preferablyabout 7%, still even more preferably about 7.5%, still even morepreferably about 8%, still even more preferably about 8.5%, still evenmore preferably about 9%, still even more preferably about 9.5%, stilleven more preferably about 10%, still even more preferably about 10.5%,still even more preferably about 11%, still even more preferably about11.5%, still even more preferably about 12%, still even more preferablyabout 12.5%, still even more preferably about 13%, still even morepreferably about 13.5%, still even more preferably about 14%, still evenmore preferably about 14.5%, still even more preferably about 15%, stilleven more preferably about 15.5%, still even more preferably about 16%,still even more preferably about 16.5%, still even more preferably about17%, still even more preferably about 17.5%, still even more preferablyabout 18%, still even more preferably about 18.5%, still even morepreferably about 19%, still even more preferably about 19.5%, still evenmore preferably about 20%, still even more preferably about 20.5%, stilleven more preferably about 21%, still even more preferably about 21.5%,still even more preferably about 22%, still even more preferably about22.5%, still even more preferably about 23%, still even more preferablyabout 23.5%, still even more preferably about 24%, still even morepreferably about 24.5%, and still even more preferably about 25%. Theshaped confectionery centers have a percent density reduction of about5% to about 25%, preferably about 5.25% to about 25%, more preferablyabout 5.25% to about 20%, even more preferably about 5.5% to about 20%,still even more preferably about 6% to about 15%, still even morepreferably the percent density reduction is about 6.5% to about 15%, andmost preferably about 7% to about 10%.

Other methods may be employed to manufacture a product having a centerwith a percent density reduction of at least about 5%.

For example, in one method a fat based confectionery center such aschocolate may be aerated to a target density reduction of 5% or higher.The aerated chocolate could then be deposited in a chocolate mold. Themold may have two parts, which would then be combined to form a “bookmolded” piece, thus forming a solid center. Alternatively, a top andbottom mold could be secured together (e.g. with magnets) and theaerated chocolate could be added through a small hole in the top mold,thereby forming a single center. The molds would then be chilled to setthe chocolate without being subjected to vibration, which could causethe air to escape from the chocolate. The centers would later be removedfrom the mold and delivered to a panning operation to apply a sugarshell.

Another method would be to deposit a fat based material, e.g. chocolate,into a mold, which is manipulated to create a void in the formedcenters. For example, shell molding may be used where chocolate isdeposited into a shell mold and inverted to remove excess chocolate,leaving a chocolate shell. The chocolate is cooled and then book moldedto form the center. In another embodiment, centers could be made using aspin molding process. Chocolate for the shell is deposited into one partof a mold, which is then sealed and continuously spun. The chocolate ischilled to set its shape. In yet another embodiment, cold presstechnology may be used. Here, a cold press is pushed into a moldconfigured to form one half of the center, containing chocolate to formand set a “shell.” Two such shells may be formed into a single center bywarming the rims of the shell, placing them together then cooling themforming a solid welded piece. The formed centers would then be panned tocreate a sugar shell.

Though these options could be used to create a sugar shelled fat basedcenter with a percent density reduction greater than 5%, they would be(a) slow and (b) expensive. As such, these methods are impracticalespecially for making bite-sized lentil shapes.

The invention also includes a panned sugar shelled confectionery producthaving a center that has a percent density reduction of at least about5%. The density reduction may be achieved by creating one or more voidsin the center. For example, there may be 1, 2, 3, 4, or 5 voids in thecenter. The voids may be visible, partially visible, homogenous, ornon-homogenous.

As previously discussed, the shelled shaped confectionery product of theinvention is subjected to thermal cycle testing to demonstrate therobustness of the product.

It is desirable that the panned sugar shelled confectionery productexhibit about 70% or less cracking and bleeding when subjected tothermal cycle treatment. To test the product, the product is placed in atemperature control chamber where the temperature of the chamber iscycled from a temperature of 45° C. for a period of 8 hrs to atemperature of 20° C. for a period of 16 hrs.

Thermal Cycling Test Method

Product in good condition, i.e., without visible cracks and fatbleeding, is placed in a Model 818 Precision™ Brand Incubator(temperature controlled chamber) for at least one thermal cycle, i.e.,24 hrs. During the 24 hour period, the temperature is cycled from 45° C.to 20° C. Initially the temperature is set at 45° C. for 8 hrs and thenthe temperature setting is lowered to 20° C. for the next 16 hrs. Therate of cooling in the chamber is about 0.41° C./min. The product can betreated to more rigorous testing by keeping the product in the chamberfor two, three or four cycles. In such a case, at the end of a cycle,the product is raised from 20° C. to 45° C. at a heating rate of about0.47° C./min.

The shaped confectionery product of the invention performed extremelywell during thermal cycle testing. In Example 1, 0% of product madeusing the forming pin cracked and bled after one cycle of thermal cycletesting. Just as remarkable is that only 3% of the product made usingthe invention, cracked and bled after 4 cycles.

By utilizing the forming pin, less than about 70% of the resultingproduct will crack and bleed after thermal cycle treatment. Preferablyless than about 60%, more preferably less than about 50%, even morepreferably less than about 40%, still even more preferably less thanabout 30%, still even more preferably less than about 20%, still evenmore preferably less than about 15%, still even more preferably lessthan about 10%, still even more preferably less than about 5%, stilleven more preferably less than about 3%, and most preferably about 0%will crack and bleed after thermal cycle treatment. Multiple thermalcycle treatments (2 cycles, 3, cycles, 4 cycles, etc.) will producesubstantially similar results.

Density Test Method

To measure the density (as specific gravity) of the shaped confectionerycenters, an analytical balance equipped with a density measurement kitspecific to that balance is used. The centers are weighed in air andthen weighed while submerged in a suitable liquid of known density.Analysis is performed using an analytical balance (Mettler ToledoAT-201), density measurement kit (Mettler Toledo 210485), and athermometer with a scale of 10° C. to 50° C. (0.1° C. gradations). Ethylalcohol is used as the reagent. The procedure set forth below isfollowed where (1) the density measurement kit is installed on thebalance, (2) the low-form beaker is filled with enough ethyl alcohol tocompletely cover the sample, (3) the thermometer is suspended in thebeaker, (4) the solids sample holder is suspended on the bracket withthe basket immersed in the alcohol, (5) the balance is tared, (6) thesample is mixed-well and ten centers are placed on the upper weighingpan and the weight is noted, (7) the balance is tared again, (8) thecenters are removed from the upper weighing pan and placed in the lowerweighing basket and immerse in the alcohol, and (9) the displayed weight(buoyancy) of the centers is noted.

The density reduction is then calculated by (a) dividing the weight ofthe centers in step (6) by the weight of the centers in step (9), (b)determining the corrected density of alcohol, (c) multiplying the resultof step (a) by the density of alcohol, (d) repeating the procedure aboveand taking the average as specific gravity.

Note that the specific gravity of pure ethyl alcohol is 0.78934 at 20°C. To determine the density of ethyl alcohol at another temperature,tables found in standard chemistry textbooks may be used.

Comparative Example 1

A panned sugar shelled chocolate centered confectionery product wasmanufactured using a cold forming apparatus, where chocolate flakes weredeposited into a set of forming rolls. The chocolate centers formed hada 13 mm width and depth and a depth of 9.2 mm.

The chocolate centers were then treated to a hard panning operationwhere a sugar shell coating was applied over the chocolate centers. Theamount of sugar shell coating applied was about 32% of the total weightof the product.

The resulting product was examined to select pieces that did not havevisible cracks or fat bleeding through the shell. The product selectedwas then subjected to thermal cycle treatment. Each cycle consisted ofheat treating the product for 8 hrs at a temperature of 45° C. and thenlowering the temperature to 20° C. for 16 hrs. Samples were cycled 1, 2,3 and 4 times. The results are presented in Table 1.

TABLE 1 Percentage exhibiting Sample # # of Cycles Cracks and Bleeding*Sample 1 1 75% Sample 2 2 93% Sample 3 3 95% Sample 4 4 90% Based on a40 piece sample size tested for each cycle

Example 1

A panned sugar shelled confectionery product was made following theprocedure of Comparative Example 1, except that the chocolate centerswere formed in an apparatus that utilized the forming pin of theinvention. The use of the forming pin resulted in confectionery centersthat had a percent density reduction of about 4.65%. The experimentalcenters had a 13 mm length and width and a depth of 9.2 mm. The formingpocket was designed to form a lip or tail, which sealed the opening inthe rolling step. The forming pin was cylindrical and had a depth andwidth of 2 mm. The length of the body of the forming pin was configuredto extend just beyond the top and bottom of the forming pocket whencentered at the nip. The centers were then sugar shelled in a hardpanning operation where the amount of sugar shell coating applied wasabout 32% by weight of the total weight of the product. The resultingsugar shelled confectionery centers were examined to select pieces thatdid not crack or displayed fat bleeding through the shell. The selectedpieces were then subjected to the same heat cycle treatment described inComparative Example 1. The results are presented in Table 2.

TABLE 2 Percentage exhibiting Sample # # of Cycles Cracks and Bleeding*Sample 1 1 0% Sample 2 2 0% Sample 3 3 0% Sample 4 4 3% Based on a 40piece sample size tested for each cycleComparative Example 1 and Example 1 demonstrates the robustness of theproduct made using the invention, which exhibits dramatically lesscracking and fat bleeding when subjected to thermal cycling, e.g.temperature changes.

Comparative Example 2

Tempered chocolate from an Aasted tempering system was fed into aholding tank. Chocolate was pumped from the holding tank to an aerationhead, which was supplied with a gas. The pressure on the aeration headwas approximately 4 bars. Chocolate was continuously circulated throughthe aeration head and back into the tank. Circulation of the chocolatecontinued in this manner until the target aeration level was achieved,about 12.5%. Once the target aeration level was achieved, or the maximumlevel of aeration was reached—about 10% in this test, the chocolate wasdiverted from the holding tank to the top of a set of chilled formingrolls. The rolls had forming pockets of 12.9 mm width and length, and 6mm depth. The chocolate was then processed through the chilled formingrolls to form lentil shaped centers. A sample of the aerated chocolatefed to the rolls was collected, to determine the percent aeration. Thelentil shaped centers formed were also evaluated to determine thedensity of the pieces, using the Density Test Method protocol. Thesample was allowed to solidify before analysis. Testing was performedusing nitrogen gas and compressed air. The results of the testing areprovided in Table 3.

TABLE 3 % Width and Aeration Comparative Depth Length Density in %Density Sample (mm) (mm) (g/ml) Chocolate Reduction Control 6.08 12.87 ×12.87 1.29 0.0 0.0 1 6.18 12.81 × 12.81 1.23 7.75 4.65 2 5.92 12.84 ×12.84 1.27 6.20 1.55The percent density reduction of the formed lentil shaped centers wassignificantly lower than the percent aeration in the chocolate fed intothe chilled forming rolls. The compressive forces of the forming rollsappear to reduce the amount of gas trapped in the chocolate, loweringthe percent aeration. The highest percent density reduction achieved wasonly 4.65%.

Example 2

A chocolate centered confectionery product was manufactured, wherechocolate flakes were deposited into a set of forming blocks compressingand compacting the flakes into a cohesive lentil shape. Two formingblocks had forming pockets in corresponding alignment, where the formingpockets were approximately 12.9 mm in width, 12.9 mm in length, and 6 mmin depth. A forming pin was placed in a groove traversing the formingpockets. Pressure was applied to the two forming blocks using ahydraulic press to compact and compress the chocolate flakes into aunified cohesive piece. The pin was removed from the formed pieces inthe forming blocks. The formed pieces were then removed from the blocks.The void left by the pin was sealed manually by smoothing chocolateflakes over the ends of the void. The formed pieces, i.e. chocolatecenters, formed had a 12.9 mm width and length, and a 6 mm depth. Table4 shows the results of testing performed using forming pins of differentwidths and lengths, resulting in various levels of percent densityreduction.

TABLE 4 Cylindrical Pin Width and Depth % Density Sample (mm) Density(g/ml) Reduction Control None 1.2985 0.00% 1 1.57 × 1.57 1.2468 3.98% 22.31 × 2.31 1.1943 8.02% 3 2.63 × 2.63 1.1778 9.30%By using the forming pin, much higher levels of density reduction wereachieved over traditional aeration methods, which at best only achieveda percent density reduction of 4.65%.

While the invention has been described above with reference to specificembodiments thereof, it is apparent that many changes, modifications,and variations can be made without departing from the inventive conceptdisclosed herein. Accordingly, it is intended to embrace all suchchanges, modifications, and variations that fall within the spirit andbroad scope of the appended claims. All patent applications, patents,and other publications cited herein are incorporated by reference intheir entirety.

1. A process for manufacturing a shaped confectionery product,comprising the steps of: (a) providing a fat based material to a formingapparatus, wherein said forming apparatus comprises (i) first and secondforming rolls with forming pockets in corresponding alignment, whereinat least one roll has one or more continuous grooves provided in thesurface of the roll such that each continuous groove extends around thecircumference of the roll in a plane perpendicular to the longitudinalaxis of the roll and intersects a plurality of discrete forming pocketsintersected by said plane, and wherein the first and second formingrolls rotate counter to one another; and (ii) one or more forming pinspositioned between the counter rotating rolls and within the continuousgroove of the roll; (b) forcing said fat based material through saidforming apparatus, thereby substantially forming said shapedconfectionery product; and (c) optionally, cooling said shapedconfectionery product.
 2. The process of claim 1, wherein said shapedconfectionery product has a lip protruding in a region adjacent to ahole formed by the forming pin.
 3. The process of claim 1, furthercomprising at least one of the steps of (i) deflashing a webbing formedduring said forcing step, or (ii) rolling said shaped confectioneryproduct.
 4. The process of claim 1, wherein at least one of thefollowing conditions is met: (i) the fat based material is a freeflowable particulate material, (ii) the fat based material is chocolate,(iii) the forcing step is achieved by compacting and compressing the fatbased material, or (iv) the shaped confectionery product has a lip whichis rolled in to cover a hole formed by the forming pin, during a rollingstep.
 5. The process of claim 1, further comprising the step ofinjecting a filling through said forming pin into said shapedconfectionery product.